Method of installing a mastic joint

ABSTRACT

A method of installing mastic joints on a paved surface is described. The method of installing mastic joints may be used as a repair (i.e. erosion of the paved surface at the joint) or in connection with a new installation of the paved surface. The method of installing mastic joints made include installation with joints that have a structure at the joint terminus. The method produces a joint that is resistant to infiltration of water, fuel, and salt, including mixtures thereof. The method further produces a mastic joint that is thermally resistant and produces longevity of use.

This application claims the benefit of U.S. Provisional Application No.63/310,664 entitled “METHOD OF INSTALLING A MASTIC JOINT” filed Feb. 16,2022, which is incorporated by reference in its entirety.

BACKGROUND

Paved surfaces (roadways, parking lots, driveways, sidewalk, trails, andpatios) of concrete or asphalt that include joints between portions ofthe paved surface, are susceptible to erosion (e.g. concrete spallingand subbase failures) in, at, and around the joints. Erosion occurs whenwater, fuel, or salt, and combinations thereof, contacts the joint,where the water, fuel, or salt and combinations thereof infiltrates thejoint and the seam between the joint and paved structure to erode thepaved surface and the subbase (e.g. gravel or dirt) underneath the pavedsurface. This erosion weakens the structural integrity of the pavedsurface leading to crumbling or fracturing of the paved surface. Erosionis hastened by temperature changes (freezing and thawing) of the groundthat cause movement and breakage of the paved surfaces, in particular,at the joints of paved surfaces.

This damage produces an uneven surface affecting the ability to easilytravel over and around the paved surface on foot or in a vehicle. Thedamage produced from this erosion effects the usability and safety ofthe paved surface decreasing the amount of time before repair orreplacement.

Conventional methods for installing and repairing joints of pavedsurfaces include using tar-based materials that are installed in thepaved surface joints. The installation of these tar-based materialsincludes installing backer rod and then placing tar-based material belowthe paved surface, such that the height of the tar-based material isless than the height of the paved surface (i.e. not flush with the pavedsurface). Installation in this manner is done because the tar-basedmaterial does not adhere to the paved surface, so any tar-based materialflush with or above the paved surface is more easily caught and peeledout of the paved surface by traffic (e.g. vehicles, snow plows)traversing the paved surface. Additionally, installation of the tar atthe top of the paved surface speeds the peeling of the tar-basedmaterial when the paved surface is treated with salt. The salt treatmentdraws moisture (water) out of the tar-based material, drying thetar-based material, and in combination with being level at the pavedsurface hastening peeling. Installation of the tar-based material in theconventional manner has the drawback of allowing erosion at the jointbecause water can pool and infiltrate at the low point of the tar-basedmaterial at the joint. Longevity for tar based applications isapproximately one (1) to two (2) years in length, where after this timeerosion requires replacement of material.

Similar to tar-based materials, another conventional method forinstalling and repairing joints of paved surfaces includes usingpolyurethane, silicone, and caulk materials (referred to as caulk) thatare installed in the paved surface joints. The installation of caulkincludes installing the caulk material below the paved surface, suchthat the height of the caulk material is less than the height of thepaved surface. Installation in this manner is done because the caulkmaterial does not adhere to the paved surface, so any amount of materiallevel with or above the surface is more easily caught and peeled out ofthe paved surface by traffic (e.g. vehicles, snow plows) traversing thepaved surface. Longevity for polyurethane, silicone, and caulk materialsis approximately one (1) to two (2) years in length, where after thistime erosion requires replacement of material.

Additionally, installation of the caulk at the top of the paved surfacespeeds the peeling of the polyurethane material when the paved surfaceis treated with salt. The salt treatment draws moisture (water) out ofthe caulk, drying the polyurethane material, and in combination withbeing level at the paved surface hastening peeling. Installation ofcaulk in this manner has the drawback of allowing erosion at the jointbecause water can pool and infiltrate at the low point of the caulk atthe joint.

While caulk is designed to provide a watertight seal against the joint,the caulk is not temperature resistant, nor salt resistant, and as thepaved surface fluctuates the caulk is pulled away from the structureand/or concrete producing holes to open the paved surface to water,salt, and fuel, hastening erosion.

Another conventional method of repairing a paved surface joint includesapplying cold patch to the eroded joint. Cold patching damaged jointsdoes provide a level surface. However, the cold patch is not waterproof,so immediately after patching water begins the erosion process both atthe joint and where the cold patch meets the concrete or asphalt.Additionally, the cold patch does not adhere to the paved surface suchthat fluctuations in temperature cause the cold patch to be pushed outof the joint, further leading to erosion from water, fuel, and saltexposure. Moreover, cold patches are not conventionally used along theentire length of a joint because of the inability of the cold patch towithstand temperature fluctuations. Longevity of the cold patch isapproximately six months to one year in length, where after this timeerosion requires replacement of the cold patch.

Another conventional method for repairing the joint and paved surface iscomplete replacement of the portion of the paved surface that containserosion to ultimately create new joints. However, the new paved surfacewill immediately after installation begin the erosion process at thejoints of the structure. Additionally, complete replacement of the pavedsurface is time consuming (paved surface replacement requiresapproximate cure times as follows: 1 day to receive foot traffic, 3 daysto receive light traffic, 7 days to receive heavy traffic (i.e. semis),and 28 days to reach full strength) and requires more material thanrepairing or patching the joint.

It is therefore desirable to have a method for repairing the joints ofpaved surfaces that provides longevity of use (i.e. more than one yearbefore another repair must be made, and preferably more than two yearsand up to 10 years before another repair must be made). It is furtherdesirable to have a method of repairing or installing joints of pavedsurfaces that is resistant to damage (i.e. cracking, creation of a gap)during temperature changes. It is further desirable to have method ofrepairing or installing joints of paved surfaces that takes less thanthree hours to complete repair. Finally, it is desirable to have amethod of repairing or installing joints of paved surfaces that arelevel with the paved surface to reduce erosion contributing to longevityof use.

SUMMARY

In aspects, a method of installing a mastic joint that is water, fuel,salt, and temperature resistant at a paved surface, the method includingcutting the paved surface based on predetermined parameters forming ajoint, the predetermined parameters comprising a width from 0.9525 to5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the joint; preparing the joint; applying hot mastic tothe joint to install the mastic joint, the applying comprising mixing amastic base that is hot with a bulking stone, where the bulking stone isfrom 20% to 40% of the mastic joint.

In aspects, the method of paragraph [0010], wherein the paved surface isa surface material of concrete.

In aspects, the method of paragraph [0010], wherein the paved surface isa surface material of asphalt.

In aspects, the method of paragraph [0010], wherein preparing the jointcomprises applying denatured alcohol to the adjacent paved surface.

In aspects, the method of paragraph [0011], wherein the minimum depth isequal to the depth of the paved surface.

In aspects, the method of paragraph [0010], wherein the width is from0.9525 to 4.0 centimeters.

In aspects, the method of paragraph [0010], wherein the width is from0.9525 to 3.175 centimeters.

In aspects, the method of paragraph [0010], further comprising cuttingthe paved surface based on predetermined parameters forming a secondjoint, the predetermined parameters comprising a width from 0.9525 to5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the second joint; preparing the second joint; applyinghot mastic to the second joint to install a second mastic joint, theapplying comprising mixing a mastic base that is hot with a bulkingstone, where the bulking stone is from 20% to 40% of the second masticjoint, wherein the application forms a mastic joint intersection betweenthe mastic joint and the second mastic joint.

In aspects, a method of installing a mastic joint that is water, fuel,salt, and temperature resistant at a paved surface where the mastic joinhas a structure at its terminus, the method comprising forming the pavedsurface based on predetermined parameters forming a joint, thepredetermined parameters comprising a width from 0.9525 to 5.080centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the joint; preparing a joint; applying hot mastic tothe joint to install the mastic joint, the applying comprising mixing amastic base that is hot with a bulking stone, where the bulking stone isfrom 25% to 40% of the mastic joint.

In aspects, the method of paragraph [0016], wherein the paved surface isa surface material of concrete.

In aspects, the method of paragraph [0016], wherein the paved surface isa surface material of asphalt.

In aspects, the method of paragraph [0016], wherein preparing the jointcomprises applying denatured alcohol to the adjacent paved surface andstructure.

In aspects, the method of paragraph [0017], wherein the minimum depth isequal to the depth of the paved surface.

In aspects, the method paragraph [0016], further comprising forming thepaved surface based on predetermined parameters forming a second joint,the predetermined parameters comprising a width from 0.9525 to 5.080centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the second joint; preparing the second joint; applyinghot mastic to the second joint to install a second mastic joint, theapplying comprising mixing a mastic base that is hot with a bulkingstone, where the bulking stone is from 20% to 40% of the second masticjoint, wherein the application forms a mastic joint intersection betweenthe mastic joint and the second mastic joint.

In aspects, a mastic joint of a paved surface, the mastic jointcomprising, parameters that provide water, fuel, salt and thermalresistance, where the parameters comprise a width from 0.9525 to 5.080centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the joint; wherein the mastic joint is produced bymaking a joint of the paved surface to the parameters; preparing ajoint; applying hot mastic to the joint to install the mastic joint, theapplying comprising mixing a mastic base with a bulking stone, where thebulking stone is from 20% to 35% of the mastic joint.

In aspects, the method of paragraph [0013] wherein preparing the jointfurther comprises applying a primer to the adjacent paved surface.

FIGURES

FIG. 1 is a method of installing a mastic joint for a paved surface.

FIG. 2 represents a mastic joint along the length of the mastic joint.

FIG. 3 represents a vertical cross section of a mastic joint showing themastic joint is substantially level with the adjacent paved surface.

FIG. 4 represents mastic joints along the length of each respectivejoint showing an intersection of the mastic joints.

DETAILED DESCRIPTION

As used herein, the following terms have the accompanying definedmeaning:

“Mastic” means a material for hot application that is a polymer binderwith factory blended fillers, fine aggregate, and fibers, includingreinforcing (bulking) stone (e.g. granite aggregate) having thecapability of (1) withstanding motor vehicle (including semis) weightwithout deformation of the mastic, (2) adhering to surface material andany structure at the terminus of a joint, (3) preventing melting ordeteriorating of the surface material or the plastic of any structure atthe terminus of a joint, (4) resisting water, fuel, and salt (i.e. themastic resists infiltration by water, fuel, salt, and mixtures thereof),(5) resisting thermal fluctuations (i.e. the mastic remain flexibleunder temperature changes to maintain adhesion to the surface material).

“Bulking stone” means a fine aggregate that provides volume when addedto the mastic, where the fine aggregate is from 0.3175 to 0.635centimeters (0.125 to 0.25 inches). The bulking stone may be of anymaterial that is non-reactive with the mastic, such as, granite, quartz,limestone, pea gravel, and the like.

“Joint” means the area between portions of a paved surface.

“Surface material” means the material of a paved surface and includesconcrete or asphalt.

“Structure” means a fabricated installation that includes steel and mayinclude concrete, where the steel and/or concrete is in contact with thesurface material concrete or asphalt. For example, structures includemanholes, spill buckets, and fuel islands, where the fuel islandincludes canopy column(s), fuel pump island, and bumper posts.

A method of installing mastic joints on a paved surface is described.The method of installing mastic joints may be used as a repair (i.e.erosion of the paved surface at the joint) or in connection with a newinstallation of the paved surface. The method of installing masticjoints made include installation with joints that have a structure atthe joint terminus. The method produces a joint that is resistant toinfiltration of water, fuel, and salt, including mixtures thereof. Themethod further produces a mastic joint that is thermally resistant (i.e.the mastic remains flexible at varying temperatures such that adherenceof the mastic to the adjacent surface material is maintained). Inrepairs, the mastic joint of the method provides longevity of use of atleast one year and up to 5 years prior to any repair or replacement. Innew installations, the mastic joint provides longevity of use of atleast 1 year and up to 10 years prior to any repair or replacement whenin regions having a freeze and thaw cycle similar to that of the Midwestregion. Finally, the method of installing a mastic joint does not affectthe structural integrity of the adjacent or surrounding paved surface,where the adjacent or surrounding surface material does not requirerepair or replacement sooner than if the method had not been deployed.

FIG. 1 represents a method 100 of installing a mastic joint on a pavedsurface. In 102, the paved surface is prepared. When installing a masticjoint as a repair, the paved surface is cut with a saw or routerconfigured for cutting the surface material type according topredetermined parameters of the mastic joint. When installing a masticjoint as part of a new installation, the paved surface may be preparedas described in connection with a repair, or the surface material of thepaved surface is prepared (e.g. concrete is poured) according topredetermined parameters of the mastic joint. The parameters of themastic joint include placement of the joint to provide that the joint iswater, salt, fuel (including mixtures of water, salt, and fuel thereof)and thermally resistant, which provide longevity of use as erosion issignificantly delayed or prevented by such resistances. The parametersof the mastic joint also require the mastic joint to not adverselyaffect the adjacent and surrounding surface material of the pavedsurface. The parameters of the mastic joint further provide placement ofthe joint to prevent cracking and peeling of the mastic from the joint.

The parameters of the mastic joint that provide water, salt, fuel (andmixtures thereof) and thermal resistance are a width and depth of themastic joint. The width of the mastic joint is from 0.9525 to 5.080centimeters (0.375 to 2.00 inches (in.)). Preferably, the width of themastic joint is from 0.9525 to 4.0 centimeters (0.375 to 1.5748 in.),and most preferably, the width of the mastic joint is from 0.9525 to3.175 centimeters (0.375 to 1.25 in.). The width (in connection with thedepth) ensures that there is sufficient area between the adjacentsurface material to install the mastic joint according to the method 100for adherence of the mastic joint to the adjacent surface material,including the surface material or subbase below the joint. For example,the width 204 of the mastic joint of FIGS. 2 and 4 is from 0.9525 to3.175 centimeters for the mastic joint 200.

The width is also determined by correcting any existing erosion whilenot exceeding the maximum width of 5.080 centimeters (2.00 inches),while selecting a width as close to the preferred widths as possible tostill correct the erosion. For example, in a repair if erosion of thejoint is of a width greater than 2.54 cm (1 in.) a width greater than2.54 cm and less than 5.080 centimeters (2.00 inches) is selected, mostpreferably of 3.175 cm (1.25 in.) if this preferred width will removeerosion of the paved surface. If the most preferred width will notremove erosion of the paved surface the preferred width is evaluated todetermine if this preferred width will remove erosion.

The parameter of depth of the mastic joint provides water, fuel, salt,and thermal resistance is determined based on the surface materialdepth. The mastic joint may be full depth of the paved surface (i.e. thedepth down to the subbase). The mastic joint may be partial depth of thepaved surface. In instances where the mastic joint is partial depth, theminimum depth of the mastic is at least and including 2.54 centimeters(1 inch) to provide the water, fuel, salt and thermal resistances. Whenthe mastic joint is used as a repair, partial depth repair is not donewhen the surface material that would be directly below the mastic jointshows signs of erosion or damage, such that the surface materialdirectly below the joint must be intact without erosion for a partialdepth replacement. Preferably, when the mastic joint is installed aspart of a new installation, the mastic joint depth is at least from 2.54centimeters (1 inch) or greater. For example, FIG. 3 shows the masticdepth 206 of the joint 200.

The parameter of width and depth must also provide a minimum surfacearea of contact with the adjacent paved surface to ensure properadhesion of the mastic to the paved surface to prevent water, salt,fuel, and combinations thereof from infiltrating the seam between themastic joint and the paved surface. Preferably, the minimum surface areaof all sides of the mastic joint (both sides and bottom) in contact withthe adjacent paved surface or subbase, as measured on a 2.54 centimeters(1 inch) cross section is 7.62 square centimeters (3 square inches).Thus, the width and depth of the mastic joint must be determined to meetthis minimum surface area. For example the sides making up the surfacearea are represented by 308 in FIG. 3 .

The parameter of levelness of the mastic joint with the paved surfaceprovides protection from cracking and peeling of the mastic joint fromthe joint. Levelness of the mastic joint means that the mastic joint issubstantially flush with the paved surface, where substantially meansthat the mastic joint extends from 0 to 5 millimeters above the pavedsurface. For example, FIG. 3 represents the joint 200 beingsubstantially flush with the paved surface 202, where the joint 200 isflush (level with) the paved surface.

In 104, a joint is prepared for receiving the mastic. The jointpreparation may include ensuring the subbase is level at thepredetermined depth, which may include removing debris, adding subbasematerial and/or smoothing the subbase. Preparation of the joint mayfurther include removal of any rust, dirt, or debris from the adjacentpaved surface, such as through sandblasting.

Preparation of the joint further includes ensuring the joint andadjacent paved surface is dry and the pores of the surface material andstructure are clean to create binding elasticity between the mastic andthe surface material and structure. Preparation of the joint includesapplication of denatured alcohol, which may be followed by applicationof a primer (e.g. mastic primer, water-based elastomeric coating andsealant that is acrylic resin) to the adjacent paved surface andstructure to promote adherence of the mastic to the adjacent pavedsurface. Preparation of the joint provides for maximum adherence of themastic to the adjacent paved surface and subbase, while using the leastamount of mastic, thus increasing the efficiency of the installationprocess.

In 106, the mastic is applied to the prepared joint forming the masticjoint. The mastic is applied in accordance with mastic manufacturerspecifications. The application of the mastic includes applying themastic to the joint hot, while mixing the mastic base (i.e. masticwithout bulking stone added) with bulking stone, where from 20%-40% ofthe mastic is bulking stone (i.e. bulking stone percentage). Morepreferably the bulking stone is from 20-35% of the mastic. Thepercentage of bulking stone in the mastic is dependent on the width andvolume of the joint, where a joint having a greater width or volumerequires a higher percentage of bulking stone of the mastic. Preferably,the mastic is not placed in lifts exceeding 7.62 centimeters (3 inches)in height to speed with cooling. Applying the mastic may include phasedapplication. Cooling of the mastic in partial depth applications to curefor receiving traffic takes approximately 1 hour for foot traffic andall vehicle traffic. Cooling of the mastic in full depth application tocure for receiving foot traffic takes approximately 30 minutes to 2hours for foot traffic and all vehicle traffic.

Preferably, the mastic is applied to the entire length of the joint,including where joints intersect. For example, as represented in FIG. 4the mastic joints are applied to the entire length of the joint,including formation of a mastic joint intersection 406. Applying masticalong the entire length of the joint reduces likelihood and speed oferosion of the adjacent paved surface.

1. A method of installing a mastic joint that is water, fuel, salt, andtemperature resistant at a paved surface, the method comprising: cuttingthe paved surface based on predetermined parameters forming a joint, thepredetermined parameters comprising a width from 0.9525 to 5.080centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the joint; preparing the joint; applying hot mastic tothe joint to install the mastic joint, the applying comprising mixing amastic base that is hot with a bulking stone, where the bulking stone isfrom 20% to 40% of the mastic joint.
 2. The method of claim 1, whereinthe paved surface is a surface material of concrete.
 3. The method ofclaim 1, wherein the paved surface is a surface material of asphalt. 4.The method of claim 1, wherein preparing the joint comprises applyingdenatured alcohol to the adjacent paved surface.
 5. The method of claim2, wherein the minimum depth is equal to the depth of the paved surface.6. The method of claim 1, wherein the width is from 0.9525 to 4.0centimeters.
 7. The method of claim 1, wherein the width is from 0.9525to 3.175 centimeters.
 8. The method of claim 1, further comprisingcutting the paved surface based on predetermined parameters forming asecond joint, the predetermined parameters comprising a width from0.9525 to 5.080 centimeters, a minimum depth from 2.54 centimeters, anda minimum surface area that contacts the adjacent paved surface andsubbase from 7.62 square centimeters as measured based on a 2.54centimeter vertical cross section of the second joint; preparing thesecond joint; applying hot mastic to the second joint to install asecond mastic joint, the applying comprising mixing a mastic base thatis hot with a bulking stone, where the bulking stone is from 20% to 40%of the second mastic joint, wherein the application forms a mastic jointintersection between the mastic joint and the second mastic joint.
 9. Amethod of installing a mastic joint that is water, fuel, salt, andtemperature resistant at a paved surface where the mastic join has astructure at its terminus, the method comprising: forming the pavedsurface based on predetermined parameters forming a joint, thepredetermined parameters comprising a width from 0.9525 to 5.080centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the joint; preparing a joint; applying hot mastic tothe joint to install the mastic joint, the applying comprising mixing amastic base that is hot with a bulking stone, where the bulking stone isfrom 25% to 40% of the mastic joint.
 10. The method of claim 9, whereinthe paved surface is a surface material of concrete.
 11. The method ofclaim 9, wherein the paved surface is a surface material of asphalt. 12.The method of claim 9, wherein preparing the joint comprises applyingdenatured alcohol to the adjacent paved surface and structure.
 13. Themethod of claim 10, wherein the minimum depth is equal to the depth ofthe paved surface.
 14. The method of claim 9, further comprising formingthe paved surface based on predetermined parameters forming a secondjoint, the predetermined parameters comprising a width from 0.9525 to5.080 centimeters, a minimum depth from 2.54 centimeters, and a minimumsurface area that contacts the adjacent paved surface and subbase from7.62 square centimeters as measured based on a 2.54 centimeter verticalcross section of the second joint; preparing the second joint; applyinghot mastic to the second joint to install a second mastic joint, theapplying comprising mixing a mastic base that is hot with a bulkingstone, where the bulking stone is from 20% to 40% of the second masticjoint, wherein the application forms a mastic joint intersection betweenthe mastic joint and the second mastic joint.
 15. The method of claim 9,wherein the width is from 0.9525 to 4.0 centimeters.
 16. The method ofclaim 9, wherein the width is from 0.9525 to 3.175 centimeters.
 17. Amastic joint of a paved surface, the mastic joint comprising: parametersthat provide water, fuel, salt and thermal resistance, where theparameters comprise a width from 0.9525 to 5.080 centimeters, a minimumdepth from 2.54 centimeters, and a minimum surface area that contactsthe adjacent paved surface and subbase from 7.62 square centimeters asmeasured based on a 2.54 centimeter vertical cross section of the joint;wherein the mastic joint is produced by making a joint of the pavedsurface to the parameters; preparing a joint; applying hot mastic to thejoint to install the mastic joint, the applying comprising mixing amastic base with a bulking stone, where the bulking stone is from 20% to35% of the mastic joint.
 18. The mastic joint of claim 17, wherein thewidth is from 0.9525 to 4.0 centimeters.
 19. The mastic joint of claim17, wherein the width is from 0.9525 to 3.175 centimeters.
 20. Themethod of claim 4, wherein preparing the joint further comprisesapplying a primer to the adjacent paved surface.